'95 XJ600 - New horse in the stable (Pic Heavy)

Two hundred dollars? - that's only £129, bloody hell.

Look how much XJ600 I could buy over here for that...

http://www.ebay.co.uk/itm/GENUINE-YAMAH ... 456wt_1163

 

great score and awesome documentation- thanks for sharing it with us!!

Congrats on the title!!

 

The front fairing has a nasty crack.


Taped the outside to hold it together and keep the cement from coming through


I use a for sale sign cut into strips for repairing plastic. It's tough and flexible.


There is some existing cement from a previously failed attempt by the P.O.


A flapper wheel on the Foredom will help with that


Much better. Softened the surface with a little acetone.


These clamps aren't mine, so I need to be considerate...I guess. :roll:


It doesn't smell Oatey, though


Liberal amount applied to the offending crack


Sign strip squished on there. Since the strip is on a bend, I put the clamps on tight and then push the strip down to form to the contour.


Not sure what I'm going to do about the back of the fairing


While that was setting, I needed to get those sync port screw out. The vice grips did the trick since they were pointy. Not a whole lotta room to move around.


Some new hardware


And washers to go with the screws. Although, what good does a package of three do? Maybe in case I lose one. Thanks for your confidence in my organizational skills, Lowes.


Much better.


I need to order a couple of these since the bike didn't come with all of them. $2.50 each though. Good thing I don't need all of them.


Because the '95 has six fairing mount points on each side.


Started to find supple materials for fabbing the belly pan hardware. Found some aluminium peices for about five bucks each at Lowes.



These little mounts will work superb once I get the bracket sized and shaped correctly. You drill a hole, stick em though, and use two little screws to anchor it.


The fairing crack is nice and secure. Gonna get some of that black cement and fill the crack.

 

I've been working on the mounting hardware for the belly pan. So far its been successful as far as lining things up, but I sure wish I had a metal shop :laughter: My methods for aluminium bending have worked so far, though. Had to be a little crafty.


Aluminium is easy to bend, but strong where it counts


Straight enough for me!


After I get a good piece, I'll measure it up so it's easy to make the second one


This is a different bracket, but you get the idea of how it will mount


Now on to the front fairing. It needs more crack repair and sanding.


The stickers must come off, but I took some high quality pictures of them if I decide to re-create them in Photoshop and have them printed.


P.I.T.A without the heat gun


I use this stuff religiously for sticky stuff removal


The sweet little air scoop screens


The sweet little air scoops


Sanded up, now to cement some cracks


With the back corner liberally cemented and reinforced, I'll let that dry tonight and sand the flugen out of it tomorrow.

 

Sanded the flugen out of the cement, now ready to prime


On my makeshift holder. Outside in the cold and wind, too :x My paintbooth isn't assembled yet


First coat of prime


Good, good


Let it dry for a while, then sanded, then a second coat of prime

 

nice work on the fairing dawg!!

 

Very nice work. The pictures really give you a sence of being there with you watching you do every step. This would help anyone who would want to try this themselves. Nice job and thanks for the posts. Keep them coming.

 

Thanks for the positive words. It has been a while since I updated, but always in motion, the future is. **yoda chuckle**


Had to fab some mounts for the belly pan


Here's what I did:

This is the mount that you mount onto the mount. The three little mountie holes were a little too small for the metal screws I got, so they needed to be manhandled a bit.



Using this whatchamacallit bit


Nice, nice


Mounted on two the front mounts. I broke the head off of one screw, eheheh.


Now for the rear mounts. Need to give them a little room for fastening.


Beautiful!


Oh joy of joys


Not the prettiest thing, but I am happy.


Cleaned up the edges a bit so it's not messing up my paint.


The rear mounts. The tape is just to keep them from scratching up the frame until I can find some suitable rubber to put behind them.


Front right


Front left. I have rubber washers that going in between the fairing and mount, so it's not pressing right up against the three screw heads. Did I even use those things right? I have no idea.


Rear right. This is just temporary until I can replace the blue tape with rubber and paint everything black


The rear left is a little tricky because of the kickstand. I'll have to make another mount that extends down the frame where I can attach another clamp. It's on there pretty good, though.


And there you have it.






(4) 1/4-20 x 1/2 round head screw for attaching belly pan
$2

Package of 4 x 3/8 zinc metal screws for fastening nutplates
$2

(4) 1/4-20 x 5/16 nutplates
$6

(4) 3/4" to 1 1/2" #16 clamps
$3

Package of 1/4" nylon washers
$1

(1) Piece of 1/8" x 3/4" x 3' aluminium
$6

Total: $20

Windscreen:


Front fairing. Once this dries, I'll wet sand and clear:

 

I was going to ride down to Daytona for bike week, but my head gasket decided to be a @&%!@. What do you expect for a bike that had been sitting with crap in the cylinders for 14 years and then I hop on and ride the dickens out of it... Bought it with 2.3K miles, currently has 3K.



Oil was leaking down the side


And ganked. The piston crowns weren't too bad.


All I need to do is replace the head gasket, but I'm going to replace the valve stem seals and lap the valves. Let no job be half done!


I should have checked that valve clearances, but oh well


Someone WILL walk by and knock all this over. Never fails.


Head is dissasembled and soda blasted. The valves need a little extra cleaning which will happen tomorrow. Here are some before shots.

Crusty valves


Baking valve muffins


This stuff is amazing. I used it to rid the head of dirt and oil. It is mainly used for cleaning my chain. Love it.


Despicable


Exhaust valve


Intake valve. Look at that unacceptable crusty.


These will look so schmexy after some lapping.


Oh the tragedy


This will not do

 

Dude, definitely keep this up! I read your whole post and it was as cool as an adv ride report, pics are awesome and so is your ability to describe all the steps you are taking with the restore! What an inspiration to all of us!

Mac

 

Thanks a bunch Mac! Plenty more to come I guarantee that.

 

Head is back on, but as you can imagine after lapping the valves and such the clearances have drastically changed. Addressing that is the next step.

Enjoy:

[flash=660,400]http://www.youtube.com/v/Is3DNOL61gw.swf[/flash]

 

Andrew
I must tell you that what you are doing in this thread will be soo beneficial to many of our members. I don't have anything to work on my bike but after going through this thread, I must say it makes me want to tear into something just so I can do it!! Please keep this up. I like the video and it is very nice to see the detail you are doing with this bike! Awesome!! Thanks.

 

That's pretty cool Andrew... Nice work

 

We all want one of those nice shops with all the expensive tools, but being skilled enough and smart enough to do the work without saves dollars for the bike. :wink: Great job, great fabrication skill. 8)

 

Great work Andrew,

Bike looks great and yeah i'm sure those pics will come in handy at some point!

BTW...

<notahijack>Thanks for the youtube link, finally figured out that flash link option! it's not you youtube anywhere!!! </notahijack>

 

Man, I do love watching your progress!

 

Thanks a bunch fellas.

Yes, all the pictures come in handy. I refer to them very often to remember how a procedure was done, or what part I used, or using them as a visual when explaining something to someone else, ect...

Oh yea, the actual title showed up in the mail today...I cried a little cry.

 

Hey guys, thought I'd show you where the bike is now.

I decided against putting the front fairing back on. No surprise, right? Well I turned it "naked"...no surprise, right? And I found a round headlight and some gauges....no surprise.....right??

Alright, some pictures. Of course, I have to wash first. You don't need to see my filth of the day.


Front view. This is a good spot for them. Good distance and angle. They're from a FZ600.


Basically, I made a aluminium mount that goes across and connects to the headlight brace.


...connecting here. This was probably the most simple mounting method, but it's very stable and looks decent.


The aluminum piece was painted with some DupliColor black engine enamel, using the "Distance Texture" method.


I like the gauges from this angle.


And from this angle. Heck, from every angle!


And a gratuitous rear shot. My Podium is almost outside the safezone.


And I finally got my '92 frame home. It had been sitting at work this whole time. This project is going to pick up real soon!

 

That is a thing of beauty